System to construct fence

ABSTRACT

A system for constructing a fence utilizes foam panels that are coated with a cementitious material and that include rebar feet that extend outwardly from the bottom of the panel. During construction of the fence the rebar feet are inserted in a wet concrete footer.

This invention pertains to fencing and methods to construct the same.

A principal object and motivation of the instant invention is to providea system to construct a fence. This general motivation has long existedand has produced a variety of patented and other systems to construct afence. As discussed below, the trends, problems, motivations, etc.associated with such designs did not provide any significant impetustoward the development of the invention.

This and other, further and more specific objects and advantages of theinvention will be apparent from the following detailed descriptionthereof, taken in conjunction with the drawings, in which:

FIG. 1 is an exploded view illustrating in part the fence constructionsystem of the invention; and,

FIG. 2 is an assembly view further illustrating the system of theinvention.

Briefly, in accordance with the invention, I provide an improved systemto construct a fence. The system includes the step of providing anH-shaped foam support column having a pair of vertically extending,spaced apart, exterior U-shaped receiving slots; a top; sides; a bottom;and, at least a first rebar including a first upper portion embedded inthe foam support and a first lower portion extending outwardly from thebottom of the foam support. The system also includes the step ofproviding an orthgonal foam panel having an upper edge; a lower edgespaced apart from and generally parallel to the upper edge; a first sideedge generally normal to the upper and lower edges; a second side edgespaced apart from the first side edge and generally normal to the upperand lower edges; a pair of spaced apart generally parallel faces boundedby the upper edge, lower edge, first side edge, and second side edge;and, at least a second rebar including a second upper portion embeddedin the foam panel and a second lower portion extending outwardly fromthe lower edge of the foam panel. The system also includes the steps ofcoating at least the sides and top of said H-shaped foam support columnwith a cementitious material to produce a ready-to-install fence supportcolumn; coating at least the faces and the top and side edges of theorthgonal foam panel with a cementitious material to produce aready-to-install fence panel; transporting the ready-to-install fencesupport column and the ready-to-install fence panel to a constructionsite; excavating a footer trench at a selected location at theconstruction site; pouring wet concrete into the footer trench;installing the fence support column by pressing the first lower portioninto the wet concrete until the bottom of the support column contactsthe wet concrete; and, installing the fence panel by sliding one of thefirst and second side edges of the fence panel into and down one of theexterior U-shaped receiving slots of the fence support column to pressthe second lower portion into the wet concrete until the lower edgecontacts the wet concrete. The orthogonal foam panel can be constructedby providing at least first and second foam members; forming at leastone groove in at least the first foam member to receive the upperportion of the second rebar; and, inserting the upper portion of thesecond rebar in the groove; and connecting the second foam member to thefirst foam member to cover the groove and the upper portion of thesecond rebar, sandwich the upper portion of the second rebar between thefirst and second foam members, and permit the lower portion of thesecond rebar to extend outwardly from the first and second foam members.

Turning now to the drawings, which depict the presently preferredembodiments of the invention for the purpose of illustrating thepractice thereof and not by way of limitation of the scope of theinvention, and in which like reference characters refer to correspondingelements throughout the several views, FIG. 1 illustrates the presentlypreferred process for constructing a foam panel utilized in the systemof the invention. STYROFOAM™ polystyrene plastic pieces 10 and 20, orpieces fabricated from some other desired foam material (preferably alightweight foam material), are provided. Piece 10 preferably, but notnecessarily, has a shape and dimension equivalent to that of piece 20.The shape and dimension of pieces 10 and 20 can vary as desired, but theorthogonal configuration depicted in FIGS. 1 and 2 is presentlypreferred. A groove pattern 11 is cut or otherwise formed on the innerface of piece 10. Pattern 11 is shaped and dimensioned to receive andseat the lower half of a rebar lattice 12. A similar groove pattern 21is formed on the inner face of piece 20 that opposes pattern 11. Groovepattern 21 has a shape and dimension equivalent to that of pattern 11such that when the inner face of piece 20 is glued or otherwise fastenedto the inner face of piece 10 and is in registration with piece 10,grove pattern 21 is in registration with groove pattern 11 and the upperhalf of lattice 12 seats in groove pattern 21. If desired, the groovepattern can be formed on the inner face of only one of pieces 10 and 20.

Lattice 12 is shaped and dimensioned such that when pieces 10 and 20 areattached in this way, feet 13, 14, 15 extend outwardly from pieces 10and 20 in the manner illustrated in FIG. 2. Lattice 12 includes at leastone piece of rebar. The manufacture of lattice 12 typically requiresthat straight pieces of rebar be spaced apart and laid over one anotherin a pattern similar to that shown in FIG. 1. The pieces of rebar arethen wired or welded together at the points at which pieces of rebarintersect. Such a production method is time consuming and laborintensive. In accordance with one embodiment of the invention, each foamsupport member 18 and/or orthogonal foam panel 28 includes at least oneU-shaped piece 50 (FIG. 2) of rebar with feet 13, 15. Two or moredifferent sized U-shaped pieces 50, 51 of rebar (FIG. 2) can be utilizedin a foam panel 28 such that one U-shaped piece of rebar is nested inand spaced apart from another U-shaped piece of rebar to produce four ormore feet 13, 52, 53, 15 extending outwarding from panel 28. Or agenerally U-shaped piece of rebar can be utilized that includes only asingle foot 13, 15 that extends outwardly from panel 28, i.e., one endof the rebar is contained completely within panel 28. The utilization ofU-shaped pieces of rebar significantly simplifies the production ofrebar members utilized in a penl 28.

When pieces 10 and 20 are attached to one another with lattice 12sandwiched therebetween an orthogonal foam panel 28 is produced.

A pair of foam pieces which have a generally T-shaped cross section andhave an equal shape and dimension can, in a manner similar to that ofpieces 10 and 20, be provided to form a foam support member which hasrebar seated therein and which has a generally H-shaped cross section. Agroove pattern is formed on the inner face of each T-shaped foam piecesuch that when the inner faces are glued together to form seam 71 (FIG.2), the groove pattern in one piece is in registration with the groovepattern in the other piece and the rebar is seated in the groovepatterns such that feet 16 and 17 (FIG. 2) extend outwardly from thepieces attached pair of T-shaped foam pieces.

Any other desired method can be utilized to form an orthogonal foammember or a foam support member. For example, rebar can be pushed intoan existing unitary orthogonal foam members or pushed into an existingfoam support member that has a generally H-shaped cross section. Or,rebar can be position in a mold while an orthogonal foam member isformed in the mold and extends around at least a portion of the rebar.

After an orthogonal foam member and foam support member are formed, theyare coated with a cementitious material to produce an orthogonal foampanel 28 and foam support column 18, respectively. The cementitiousmaterial can cover the entire outer surface of panel 28 and column 18,or, can only cover selected surfaces of an orthogonal foam member. or afoam support member. The cementitious material, for example stucco,preferably covers all of the outer surfaces of the foam support memberof orthogonal foam member to form column 18 or panel 28, respectively.

In one preferred embodiment of the invention, the cementitious materialis applied directly to the outer surfaces of the orthogonal foam memberand foam support member without first preparing the outer surface byapplying chicken wire or other support materials. One cementitiousmatter preferred in this embodiment of the invention is Fossil Crete™produced by Fossil Crete of 3750 Indian School road, Phoenix, Ariz.85019. This material is preferred because it forms a strong adherentcoating without requiring chicken wire and without requiring theapplication of a thick coating.

In FIG. 2, the H-shaped foam support column 18 includes a pair ofvertically extending, spaced apart, exterior U-shaped receiving slots 33and 36, a top 38, front side 30, rear side 31, left hand sides 32 and34, right hand sides 35 and 37, bottom 39, and a pair of rebar embeddedin column 18. Each rebar includes a first upper portion (not visible)embedded in the column 18 and includes a first lower portion (i.e., afoot) 16 or 17 extending outwardly from the bottom 39. Each slot 33 and36 of column 18 is shaped and dimensioned to slidably receive andsupport a side edge 44 and 45 of panel 28.

In FIG. 2, the orthogonal foam panel 28 includes upper edge 42, loweredge 43 spaced apart from and generally parallel to upper edge 42, firstside edge 44 generally normal to the upper and lower edges 42 and 43,second side edge 45 spaced apart from the first side edge 44 andgenerally normal to the upper and lower edges 42 and 43, front face 40,and back face 41. Face 41 is spaced apart from and generally parallel tofront face 40. Faces 40 and 41 are bounded by upper and lower edges 41and 43 and by side edges 44 and 45. Feet 13, 14 15 of the rebar lattice12 extend outwardly from lower edge 43.

In the system of the invention, after one or more each of panel 28 andcolumn 18 are constructed or otherwise provided, the panel 28 and column18 are transported to a selected construction site. A footer trench isexcavated in the ground 20. If desired, two-by-four or other supportscan be staked into the ground along the parallel, spaced apart edges ofthe trench to provide support for concrete that is poured in the trench.Concrete is poured in the trench to form the footer 19. The depth of theconcrete along the length of the trench preferably, but not necessarily,is equivalent to the length of feet 13 to 17. Column 18 is installed bydisplacing column 18 downwardly toward the footer 19 such that feet 16and 17 are pushed into the footer and bottom 39 contacts footer 19. Ifdesired, bottom 39 can be pressed a selected distance into the wetconcrete. A level is utilized to insure that the longitudinal verticalaxis of column 18 is normal to the ground, and, if necessary, theorientation of column 18 is adjusted to a position in which column 18 isnormal to the ground. Side edge 44 of panel 28 is slid laterally (in adirection of travel parallel to ground 20) into U-shaped slot 36 withfeet 13 to 15 above wet concrete 19. Panel 28 is then slid downwardly(in a direction of travel toward the ground) such that feet 13 to 15 arepushed into foot 19 and bottom edge 43 contacts the footer. If desired,bottom edge 43 can be pressed a selected distance into the wet concrete.A level is utilized to insure that the longitudinal vertical axis ofcolumn 18 is normal to the ground, and to insure that faces 40 and 41are normal to the ground. A plumb line can be utilized to insure thatpanel 28 and column 18 are installed along a desired fence line, whichfence line is horizontally oriented and runs along the ground. While theconcrete 19 sets, two-by-fours or other structural members can be usedto brace panel 28 and column 18 in the desired position.

As an alternative to pouring a footer, spaced apart holes can be formedin the ground to receive each foot 13 to 17 and the holes each filledwith wet concrete. The holes are spaced apart distances equivalent tothe distances between feet 13 to 17. During construction of a fenceutilizing the general method described above, feet 13 to 17 are, insteadof being inserted in a footer 19, each inserted in a different one ofthe concrete-filled holes while the concrete is still wet. It is,however, presently preferred that a footer 19, and not spaced apartholes filled with concrete, be utilized because the footer provides morestrength, particularly when the bottom edge 43 of a panel 28 is presseda selected distance into footer 19. Edge 43 can be pressed any desireddistance into footer 19, but preferably is pressed into footer 19 adistance in the range of one-half to four inches.

One particular unexpected and unpredicted benefit discovered after theinvention was developed is that it is not necessary to embed rebar in afooter and to allow the footer to harden before installing a fence. Thisis not an idea that I initially pursued and did not seem to make sense,because standard procedure dictated installing rebar or other supportsin a footer and allowing the footer to harden before fence blocks wereinstalled and before just as the idea of segmenting an individual'sspine does not make sense because it would weaken and paralyze theindividual.

Another unexpected and unpredicted benefit discovered after theinvention was developed is that the portions of the rebar extending intothe footer are sufficient to support the fence so that supplementalmechanisms do not need to be provided to interlock fence panels andfence support columns. Since other fence systems interconnect panels andcolumns, common sense initially might suggest that this would benecessary when only rebar in a wet concrete footer was being utilized tosupport the fence.

A further unanticipated benefit discovered after the invention wasdeveloped is that the cementicious coating can function as a finishcoating so that after the fence panel(s) and fence support column(s) areinstalled in a wet footer construction of the fence is complete. Thefence need not be painted or stuccoed or completed with furtherconstruction.

Unless reasons exist to the contrary, judicial notice is taken of thefollowing facts:

-   1. A dominant long felt trend exists in connection with the    construction of fencing that the footer allowed to harden before    blocks or panels or other fence construction components are    installed on the footer. This trend has occurred over an extended    period of time, is followed by a large number of individuals in the    pertinent art, and likely can be demonstrated by a significant    number of references. A countervailing trend, if any, to install    rebar simultaneously with a fence panel or support column is    believed to be much weaker or to be obfuscated among other trends in    the art.-   2. A dominant long felt trend exists in connection with the    construction of fencing that dictates that stucco or other    cementitious fence coatings be installed after the fence is    constructed. This trend has occurred over an extended period of    time, is followed by a large number of individuals in the pertinent    art, and likely can be demonstrated by a significant number of    references. A countervailing trend, if any, to apply cementitious    fence coatings before the fence is constructed is believed to be    much weaker or to be obfuscated among other trends in the art.-   3. A dominant long felt trend exists in connection with the    construction of fencing that dictates that rebar or other supports    that are partially embedded in the footer be installed in a footer    before blocks and panels and other fence construction components are    installed on the footer. This trend has occurred over an extended    period of time, is followed by a large number of individuals in the    pertinent art, and likely can be demonstrated by a significant    number of references. A countervailing trend, if any, to apply    cementitious fence coatings before the fence is constructed is    believed to be much weaker or to be obfuscated among other trends in    the art.-   4. Common sense judgment requires that valid reasoning justifying    such judgment be set forth.-   5. Common sense dictates that a footer be allowed to harden before    block or panels or other fence components are installed on the    footer.-   6. Common sense dictates that rebar or other supports that are    partially embedded in a fence footer be installed in a footer before    block and panels and other fence construction components are    installed on the footer.-   7. Common sense dictates that stucco and other cementitious coatings    by applied after a fence is constructed.-   8. There is no problem in the fence building art that provides    significant impetus for the development of the invention.    Conventional construction methods have long been accepted.-   9. There is no problem in the fence building art that suggests a    readily apparent specific set of solutions, one of which is the    invention. Conventional construction methods have long been    accepted.-   10. There is no problem in the fence building art that suggests    altering or adding to the conventional fence building methodologies.    Conventional construction methods have long been accepted.-   11. The TSM test, per KSR, can provide helpful insight into    evaluating the obviousness of the invention.-   12. There is no reason not to use the TSM test in evaluating the    obviousness of the invention described and claimed herein.-   13. Making something better is a broad, general, long-existing    motivation that applies to each invention. Broad, general,    long-existing motivations likely provide little significant impetus    to produce an invention. For example, in the exercise machine art,    one broad, general, long-existing motivation is to make exercise    machines versatile, so that more than one exercise can be produced    on an exercise machine. This motivation may provide impetus to make    obvious modifications to a machine, but provides little significant    impetus to produce an invention. If, on the other hand, an exercise    machine produces a greater than normal number of injuries, such a    problem is more specific and provides strong impetus to improve the    machine.-   14. Constructing a block wall is, for the average individual whose    vocation is not in the construction industry, difficult and is not    something that most individuals will undertake. There are several    reasons for this. First, a variety of supplies have to be obtained    including concrete, rebar, blocks, stucco mix, mortar mix, chicken    wire, trowels, shovel, level, and line. Second, the concrete,    blocks, mortar mix, and stucco mix are heavy and not readily    transported and moved to a construction site. Third, mixing mortar,    troweling mortar on blocks, and laying blocks to produce a straight,    level wall is not a simple proposition. Fourth, applying stucco is    not a straight forward matter. Fifth, cleaning up after the wall has    been constructed is a time consuming proposition.-   15. There is a common belief in the construction industry and among    people in general that a foam wall is not, even if stuccoed, strong    enough to meet the code requirements that a block wall meets.-   16. Mortaring a cement block to a solidified concrete footer is a    common practice in the construction of a fence and produces a “cold    joint” between the block and footer. Pressing a cement block into a    concrete footer while the footer is still wet would produce a “wet    joint” which would be significantly stronger than a “cold joint”.-   17. Pressing, during the construction of a fence, a cement block or    other solid cementitious structural member into a concrete footer    while the footer is wet and malleable is not practiced in the art.

Having described my invention in such terms as to enable those of skillin the art to understand and use it, and having described the presentlypreferred embodiments and best mode thereof, I Claim:

1. A system to construct a fence, comprising the steps of (a) providingan H-shaped foam support column having (i) a pair of verticallyextending, spaced apart, exterior U-shaped receiving slots, (ii) a top,(iii) sides, (iii) a bottom, and (iv) at least a first rebar including afirst upper portion embedded in said foam support column and a firstlower portion extending outwardly from said bottom of said foam support;(b) providing an orthgonal foam panel having (i) an upper edge, (ii) alower edge spaced apart from and generally parallel to said upper edge,(iii) a first side edge generally normal to said upper and lower edges,(iv) a second side edge spaced apart from said first side edge andgenerally normal to said upper and lower edges, (v) a pair of spacedapart generally parallel faces bounded by said upper edge, lower edge,first side edge, and second side edge, and (vi) at least a second rebarincluding a second upper portion embedded in said foam panel and asecond lower portion extending outwardly from said lower edge of saidfoam panel; (c) coating at least said sides and top of said H-shapedfoam support column with a cementitious material to produce aready-to-install fence support column; (d) coating at least said facesand said top and side edges of said orthgonal foam panel with acementitious material to produce a ready-to-install fence panel; (e)transporting said ready-to-install fence support column and saidready-to-install fence panel to a construction site; (f) excavating afooter trench at a selected location at said construction site; (g)pouring wet concrete into said footer trench; (h) installing said fencesupport column by pressing said first lower portion into said wetconcrete until said bottom of said support column contacts said wetconcrete; and, (i) installing said fence panel by sliding one of saidfirst and second side edges of said fence panel into and down one ofsaid exterior U-shaped receiving slots of said fence support column topress said second lower portion into said wet concrete until said loweredge contacts said wet concrete.
 2. The system of claim 1 wherein saidorthgonal foam panel is constructed by (a) providing at least first andsecond foam members; (b) forming at least one groove in at least saidfirst foam member to receive said upper portion of said second rebar;(d) inserting said upper portion of said second rebar in said groove;and (e) connecting said second foam member to said first foam member to(I) cover said groove and said upper portion of said second rebar, (ii)sandwich said upper portion of said second rebar between said first andsecond foam members; and (iii) permit said lower portion of said secondrebar to extend outwardly from said first and second foam members.